Waterproofing and vapor barrier system

ABSTRACT

A waterproofing system incorporating Polymer Rubber Gel addresses permeation of water as well as soil gases through concrete substrates. A sandwich if formed by spraying a layer of Polymer Rubber Gel between two layers of polyethylene such as Geo Textile Fleece High-density polyethylene (HDPE). This sandwich is placed between the earth and the concrete substrate.

PRIORITY

This application claims the priority benefit of U.S. Provisional Application No. 61/927,446 filed on Jan. 14, 2014, which is hereby incorporated herein by reference in its entirety.

FIELD

The present invention relates generally to systems and methods for waterproofing and providing vapor barriers for below-ground structures.

BACKGROUND

The need to provide for waterproofing of below ground or below grade structures, such as basements, is well known. Conventionally, a system of numerous drain pipes below a concrete slab is connected to one or more catch basin or pits where the water accumulates. A pump then empties the water from the basin and transmits it to a point remote from the structure. However, such systems are expensive to install, require electrical power and are failure prone. For example, a failed pump or a blocked drainage tube section can render the system ineffective.

There is also a need to control the permeation of soil gases (e.g., Radon) through the below-grade slab and walls of a structure, such as a house. Soil gas remediation systems are installed below basement slabs with increasing frequency. These systems again consist of a series of tubes placed below the slab that collect the gases, which are then vented vertically either passively or with a powered vacuum. However, such systems are once again expensive to install, require electrical power and are failure prone.

Thus, there is a need to provide a system that addresses some or all of the deficiencies discussed above.

SUMMARY

The present invention provides a unique waterproofing system that also addresses permeation of soil gases through concrete. A sandwich if formed by spraying a layer of Polymer Rubber Gel between two layers of polyethylene such as Geo Textile Fleece High-density polyethylene (HDPE).

According to certain disclosed example embodiments, a method of providing a waterproofing and vapor barrier to a concrete substrate is disclosed. The method includes disposing a first layer of polyethylene against the concrete substrate. Then a Polymer Rubber Gel material is sprayed onto the first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene. Next a second layer of polyethylene is disposed against the layer of Polymer Rubber Gel. Soil is then compacted against the second layer of polyethylene.

According to further disclosed example embodiments, a method of providing a waterproofing and vapor barrier to a concrete substrate includes spraying a Polymer Rubber Gel material onto a first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene. Then a second layer of polyethylene is disposed against the sprayed layer of Polymer Rubber Gel material. Next, the concrete substrate is formed against the second layer of polyethylene.

According to other disclosed embodiments, a method of providing a waterproofing and vapor barrier to a concrete substrate includes disposing a first layer of polyethylene against a horizontal earthen surface and then spraying a Polymer Rubber Gel material onto the first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene. Next, a second layer of polyethylene is disposed against the layer of Polymer Rubber Gel. Then a horizontal concrete slab is formed over the second layer of polyethylene.

In various embodiments the polyethylene layers may comprise a Geo Textile Fleece High-density Polyethylene (HDPE) material a Linear low-density polyethylene (LLDPE) material. Such layers can be formed by joining together individual sheets by overlapping the adjacent individual sheets and sealing a seam of the overlapped individual adjacent sheets to form a continuous layer of polyethylene. The sealing of the seam can include applying bitumen tape to the seam or heat welding the seam.

The methods herein can also include excavating soil adjacent to an outside surface of the concrete substrate to define an excavated area. A temporary earth-retaining wall can be formed in the excavated area to define a working area between the temporary earth-retaining wall and the concrete substrate.

The Polymer Rubber Gel material can be heated to an elevated temperature, such as in the range of 260-270 degrees F., before spraying the Polymer Rubber Gel material. The Polymer Rubber Gel material can be loaded into an oil jacketed kettle crack sealing pump where the temperature of the Polymer Rubber Gel inside of the oil jacketed kettle crack seal pump is elevated to liquefy the Polymer Rubber Gel. The pump delivers the liquefied Polymer Rubber Gel to an application wand under pressure. The want can include a trigger to selectively spray the liquefied Polymer Rubber Gel onto a surface by an operator.

The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a waterproofing system disposed below a horizontal concrete slab according to certain example embodiments.

FIG. 2 is a schematic perspective view of a waterproofing system applied to vertical walls according to certain example embodiments.

FIG. 3 illustrates spray application of Polymer Rubber Gel using the application wand of asphalt crack sealing equipment according to certain example embodiments.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explained with reference to various exemplary embodiments. Nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention.

Referring to FIG. 1, the waterproofing and vapor barrier system is shown according to one example embodiment. In this embodiment, the system is disposed in a horizontal orientation below a basement horizontal concrete slab. A first sheet 102 of polyethylene, such as Geo Textile Fleece High-density Polyethylene (HDPE) is laid directly against the earthen surface 104 such as soil or rock. The fleece side of the HDPE sheet 104 faces up (not towards the soil/rock).

The entire foundation footprint is covered with the HDPE material to form a single layer. HDPE material usually is commercially available in 12×30 foot rolls. The sheets are cut to length and overlapped 6-12 inches along the seams of adjacent sheets. Bitumen tape or heat welding of the seams bonds the separate adjacent sheets so that they are connected to form a single continuous layer of HDPE.

A layer of Polymer Rubber Gel material 106 is then spread atop the first layer of HDPE 102 to form a continuous layer. In one preferred embodiment, the Polymer Rubber gel is sprayed on to form a layer with a thickness of 90-100 mils.

Next, the Polymer Rubber Gel layer 106 is covered with a second layer of polyethylene 108, such as Geo Textile Fleece HDPE or Linear low-density polyethylene (LLDPE). Seams of adjacent sheets of the HDPE or LLDPE material are joined as discussed previously until the layer 108 is continuous.

The layers 102, 106 and 108 form a water and vapor barrier sandwich.

Finally, the concrete slab 110 is poured directly atop the sandwich of layers 102, 106 and 108. Rebar, or other reinforcing materials, can be placed within the concrete slab.

The Polymer Rubber Gel material is a non-curing rubber emulsion with adhesive and cohesive physical characteristics. Such material is commercially available from a variety of sources. The Polymer Rubber Gel material is applied monolithically to create an impervious waterproofing membrane. The Polymer Rubber Gel actively responds to movement of the HDPE substrates, while maintaining its exceptionally strong adhesive bond.

Polymer Rubber Gel used in forming layer 106 possesses the ability to self-heal under direct hydrostatic pressure due to its non-curing property. Polymer Rubber Gel never completely cures and remains in a state of a flexible gel. Since it never cures, it is capable of self-healing under application of hydrostatic pressure. Thus, if the waterproofing and vapor barrier system described herein were to be accidentally punctured or cut during or after installation, the Polymer Rubber Gel membrane 106 will automatically heal itself and maintain the water-tight and vapor-proof integrity of the sandwich of layers 102, 106 and 108.

Due to Polymer Rubber Gel's responsiveness to substrate movement and vibration, there is no need for repair of cracks/separation in the sandwich of layers 102, 106 and 108. In contrast, other waterproofing applications cure and crack, leading to water intrusion. The non-curing property of Polymer Rubber Gel can weather the constant stress of thermal expansion/contraction, seismic activity and vibration that might be experienced in a wide variety if applications.

The Polymer Rubber Gel layer 106 also provides for creation of a seamless or continuous layer. This, there are no seams or gaps between sections of the sandwich. There is formed a continuous membrane throughout the entire extent of the concrete slab, and potentially beyond. Thus, there are no seams or gaps where water and soil gases can easily penetrate.

The vertical side walls of a basement or other structure that are exposed to the earth can also be provided with a similar water and vapor-proof sandwich as that described above. Referring to FIG. 2, a wall membrane is formed adjacent an outside surface of the concrete basement wall 202. The HDPE sheet 204 is laid against the concrete wall. The fleece side of sheet 204 faces outward (away from the concrete). The entire wall is covered with the sheet 204 until the sheet mates with the sandwich laid under the horizontal concrete slab 110 (of FIG. 1). The wall membrane can also be used without any sandwich formed under the horizontal concrete slab 110.

Next, a continuous layer of Polymer Rubber Gel 206 is spread atop the first HDPE layer 204, typically by spraying or troweling, to a thickness of 90-100 mils. The Polymer Rubber Gel layer 206 is then covered with a second layer of HDPE 208 or a layer of LLDPE.

A temporary wall 210 can be erected prior to forming the vapor-proof sandwich in order to hold the earth back during installation, if necessary. This is often necessary when soil located adjacent the basement wall is excavated to provide access to the wall for application of the sandwich. After the sandwich of layers 204, 206 and 208 are applied to the basement wall 202, the retaining wall 210 is removed and soil is compacted against the outer HDPE or LLDPE sheet 208.

The vapor-proof sandwich can also be installed in reverse order against the excavated soil or against a temporary wall before the basement wall 202 is first erected. This method is a so-called blind installation. Blind-side installation of the vapor-proof sandwich reduces the need for excavation clearance to install the sandwich from the outside of the basement wall 202 as discussed above.

The wall membrane 200 can be joined to the slab membrane 100 along the mating seam between the two membranes where they intersect. By overlapping and detailing the seams of the intersecting HDPE/LLDPE sheets with tape, the waterproofing and vapor barrier system becomes continuous throughout its entire extents. This results in an encapsulating barrier surrounding the entire below-grade structure.

In an alternative embodiment, the wall membrane can be formed by applying the Polymer Rubber Gel layer 206 directly to the outside surface of the vertical concrete walls 202. The gel layer 206 is then covered with a single layer of HDPE/LLDPE 208. Soil can then be compacted against the HDPE/LLDPE layer 208.

In other alternatives, LLDPE sheet can be substituted for the first HDPE sheet (102 or 204).

The waterproofing and vapor barrier systems and methods described herein offer numerous advantages over other barrier systems. For example, the ease and effectiveness of installation is superior. Thus the installer can be more productive and the system is more cost effective due to reduced labor costs, speed of time to project completion and reduced mistakes in application. The present invention also offers the building or home owner peace of mind and long-term effectiveness.

Additional advantages include, the membrane does not require chemical reaction to bond to concrete, does not require hydration, and does not require compaction. The combination of Gel and sheet layers described herein creates an exceptionally durable, dynamically responsive high performance waterproofing system that is effective in many adverse soil environments and conditions. Waterproofing integrity is maintained without loss of adhesion to substrate or failure from membrane punctures as happens with conventional coating systems. Thus, a more effective waterproofing system is provided.

Conventionally, polymer rubber gels are troweled onto the target substrate surface at ambient or room temperature. This is a slow, labor intensive, mistake-prone and messy process. In contrast, an additional aspect of certain embodiments of the invention is a new method of applying the Polymer Rubber Gel by spraying it onto a substrate using asphalt crack sealing equipment (e.g., from Cimline or Crafco).

The Polymer Rubber Gel spraying procedure in certain embodiments includes loading Polymer Rubber Gel into the hopper of an oil jacketed kettle crack sealing pump. The Gel material is available on semi-solid block form at ambient room temperature, or the material can be found in more flowable forms in pails. Then the Polymer Rubber Gel is heated in the kettle to a temperature of about 260-270 degrees F., or until the Gel becomes flowable to enable spraying through the applicator wand. Once attained, the temperature is maintained for the duration of the application process. The Polymer Rubber Gel is pumped by the hydraulic pumping system of the though a discharge hose coupled to the pump. An applicator wand is attached to a distal end of the discharge hose. The Gel is delivered under pressure by the hydraulic pressure pump to the applicator wand. The wand includes a trigger to allow the user to selectively discharge or spray the Gel under pressure onto a substrate (e.g., HPDE/LLDPE sheet and concrete). FIG. 3 illustrates the spray application of Polymer Rubber Gel onto a substrate using the application wand of the asphalt crack sealing equipment. The Gel is sprayed until a continuous layer is formed with a thickness of about 90-100 mils.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention. 

What is claimed is:
 1. A method of providing a waterproofing and vapor barrier to a concrete substrate, the method comprising: disposing a first layer of polyethylene against the concrete substrate; spraying a Polymer Rubber Gel material onto the first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene; disposing a second layer of polyethylene against the layer of Polymer Rubber Gel; and compacting soil against the second layer of polyethylene.
 2. The method of claim 1, wherein the first layer of polyethylene comprises Geo Textile Fleece High-density Polyethylene (HDPE) material, and the method further comprises disposing the first layer of polyethylene against the concrete substrate with a fleece side of the HDPE material facing away from the concrete substrate.
 3. The method of claim 1, wherein the second layer of polyethylene comprises HDPE.
 4. The method of claim 1, wherein the second layer of polyethylene comprises Linear low-density polyethylene (LLDPE).
 5. The method of claim 1, wherein the first layer of polyethylene comprises a plurality of individual sheets, and the method further comprises: overlapping adjacent individual sheets; and sealing a seam of the overlapped individual adjacent sheets to form a continuous layer of polyethylene.
 6. The method of claim 5, further comprising sealing a seam of the overlapped individual adjacent sheets by applying bitumen tape to the seam.
 7. The method of claim 5, further comprising sealing a seam of the overlapped individual adjacent sheets by heat welding the seam.
 8. The method of claim 1, further comprising: excavating soil adjacent to an outside surface of the concrete substrate, thereby defining an excavated area; and forming a temporary earth-retaining wall in the excavated area to define a working area between the temporary earth-retaining wall and the concrete substrate.
 9. The method of claim 1, further comprising heating the Polymer Rubber Gel material to a temperature in the range of 260-270 degrees F. before spraying the Polymer Rubber Gel material.
 10. The method of claim 1, further comprising: loading the Polymer Rubber Gel material to an oil jacketed kettle crack sealing pump; elevating the temperature of the Polymer Rubber Gel inside of the oil jacketed kettle crack sealing pump to liquefy the Polymer Rubber Gel; and delivering the liquefied Polymer Rubber Gel to an application wand under pressure.
 11. A method of providing a waterproofing and vapor barrier to a concrete substrate, the method comprising: spraying a Polymer Rubber Gel material onto a first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene; disposing a second layer of polyethylene against the sprayed layer of Polymer Rubber Gel material; and creating the concrete substrate after disposing a second layer of polyethylene against the sprayed layer of Polymer Rubber Gel material, wherein the concrete substrate is disposed adjacent to the second layer of polyethylene.
 12. The method of claim 11, wherein the first layer of polyethylene comprises HDPE material, and the method further comprises orienting the first layer of polyethylene such that a fleece side of the HDPE material is sprayed with the Polymer Rubber Gel material.
 13. The method of claim 11, wherein the second layer of polyethylene comprises HDPE.
 14. The method of claim 11, wherein the second layer of polyethylene comprises LLDPE.
 15. The method of claim 11, wherein the first layer of polyethylene comprises a plurality of individual sheets, and the method further comprises: overlapping adjacent individual sheets; and sealing a seam of the overlapped individual adjacent sheets to form a continuous layer of polyethylene.
 16. The method of claim 15, further comprising sealing a seam of the overlapped individual adjacent sheets by at least one of applying bitumen tape to the seam and heat welding the seam.
 17. The method of claim 11, further comprising heating the Polymer Rubber Gel material to a temperature in the range of 260-270 degrees F. before spraying the Polymer Rubber Gel material.
 18. The method of claim 1, further comprising: loading the Polymer Rubber Gel material to an oil jacketed kettle crack sealing pump; elevating the temperature of the Polymer Rubber Gel inside of the oil jacketed kettle crack sealing pump to liquefy the Polymer Rubber Gel; and delivering the liquefied Polymer Rubber Gel to an application wand under pressure.
 19. A method of providing a waterproofing and vapor barrier to a concrete substrate, the method comprising: disposing a first layer of polyethylene against a horizontal earthen surface; spraying a Polymer Rubber Gel material onto the first layer of polyethylene until a continuous layer of the Polymer Rubber Gel material is formed over the first layer of polyethylene; disposing a second layer of polyethylene against the layer of Polymer Rubber Gel; and forming a horizontal concrete slab over the second layer of polyethylene.
 20. The method of claim 19, wherein the first layer of polyethylene comprises HDPE and the method further comprises orienting the first layer of polyethylene such that a fleece side of the HDPE material faces away from the horizontal earthen surface. 